Fraunhofer Research Institution for Battery Cell Production FFB
Fraunhofer Research Institution for Battery Cell Production FFB

Battery test: “Analyzing and sustainably testing batteries”

Motivation of the project

In order to transform the battery value chain into a circular economy and minimize waste, the identification of individual component materials during the production process and at the end of the battery cell's life is crucial. As part of the “Battery-Attest” project, the investigation possibilities offered by the latest developments in CT technology are to be used to make battery cell production and recycling more sustainable. 

The innovative dual-energy CT can reliably determine the composition of common cathode materials, e.g. lithium-nickel-manganese-cobalt oxides. In classically integrated CT images, as was previously the case, the only slightly differing material differences would not be visible.

Brief description

 

The project pursues the goal of the Green Battery funding priority of establishing a sustainable and closed material cycle for battery materials over the entire life cycle and enabling recyclable battery cell production. Reliable quality assurance of battery cells plays a central role in this. X-ray-based computed tomography (CT) is used as a method for non-destructive material testing, precisely because of its ability to make internal structures visible in three dimensions.

 

The three focal points of the project are

1. Creation of detailed benefit requirements

2. Production and provision of reference and defect cells

3. Demonstration and evaluation: construction of a demonstrator in the “FFB PreFab”

The project is being implemented in collaboration with various partners. VisiConsult realizes the technical setup of the inline CT system, Fraunhofer FFB defines the requirements for the test protocols and provides battery test cells. Fraunhofer IMTE is developing the reconstruction and evaluation software. The overarching goal is to make the production and recycling of battery cells more sustainable by utilizing the possibilities of the latest CT technology.

Approach

  1. Creation of a detailed user requirement.
  2. Production of pouch battery cells for testing the demonstrator.
  3. Detailed concept and prototypical realization of a high-speed CT system and a prototypical method for determining the cathode material.
  4. Hardware and software implementation of the reconstruction and evaluation.
  5. Combination of CT system and hardware and software
  6. Linking of demonstrator with a circular conveyor so that the evaluation can be carried out during operation. System integration and commissioning.

Core tasks of Fraunhofer FFB

  • Requirements definition
  • Provision of reference & defect cells
  • Evaluation of the demonstrator
  • FFB departments/groups involved:
  • Quality assurance: Internal management, coordination & processing
  • Quality management: Requirements definition and test planning
  • Process engineering: Implementation of defect integration
  • Digitization: Connection to digital infrastructure
  • Assembly: Requirements definition, design for subsequent integration in Fab
  • Cell design: Requirements definition

Utilization of results

The aim of the project is to comprehensively strengthen the metrological infrastructure and thus develop an innovative quality assurance concept for battery forming, initially primarily for pouch cells. The most important component for this is a high-speed inline CT with groundbreaking inspection options. This step not only enables improved quality assurance, but also opens up the possibility of seamless integration into the FFB factory. 

The progress made also enables qualification for round cells. Process evaluation for innovative production methods has made it possible to implement targeted recycling feeds, thereby making an important contribution to sustainability. 

Particular attention was paid to the scientific output, which generates knowledge not only for the FFB, but also for the battery production industry in a broader sense. This forms the basis for answering quality-related questions, including cause-and-effect relationships and technical-scientific issues (TecSa). 

The results achieved also serve to demonstrate the FFB innovation area and address important issues in battery production. The use of the FFB's unique infrastructure and unique selling points underlines the industrial relevance of our work and creates considerable added value for the entire industry. In this way, we have not only achieved technological progress, but also made an important contribution to the future of battery production.